Support separators for high performance communications cable with optional hollow tubes for; blown optical fiber, coaxial, and/or twisted pair conductors

ABSTRACT

The present invention includes a high performance communications cable exhibiting reduced cross-talk between transmission media that includes one or more core support-separators having various shaped profiles which define a clearance to maintain a spacing between transmission media or transmission media pairs. The core may be formed of a conductive or insulative material to further reduce cross-talk. The central core region may include a hollow opening or duct for blown fiber (ABF). A method of producing this cable introduces a core support-separator as described above into a cable assembly. The specially shaped core support-separator can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extends along the longitudinal length of the communications cable. Alternatively, with no jacket for cable completion, a portion of the separator wherein a thin layer of material can act as a type of skin for future mechanical protection may exist. The specially shaped core support-separator has a central region that is either solid, partially solid, foamed, with a solid skin over the foam or hollow itself. The cable may include a plurality of shaped sections that extend outward from the central region along the length of the central region. Each of the adjacent specially shaped sections defines a distinct clearance channel that extends along the longitudinal length of the core support-separator. Each of the defined clearance channels allow for disposal therein of conductors and/or optical fibers.

CLAIM TO PRIORITY

Applicants hereby claim priority under all rights to which they areentitled under 35 U.S.C. Section 120 based upon the U.S. ProvisionalApplication Ser. No. 60/462,983 for this patent application filed at theUnited States Patent and Trademark Office on Apr. 15, 2003.

FIELD OF INVENTION

This invention relates to high performance multi-media communicationscables utilizing paired or unpaired electrical conductors with orwithout optical fibers, and/or coaxial conductors and/or twisted pairconductors. The metal conductors and the cable itself may be shielded orunshielded or a combination of both depending on the utilityrequirements. More particularly, it relates to support-separators orspacers for cables, which may perform as self-contained cables, having acentral core defining singular or plural individual pair channels withallowance for hollow tubes that may initially be void of, or filled withone or more fiber optic, coaxial, or twisted pair conductors. The tubesor fiber ducts may be initially empty, but may be used in a futureinstallation for one or more fibers or conductors. Additionally, a pulltape may be inserted in the tubes that may be used to pull one or morefibers or other conductor(s) into an existing cable. The communicationscables have interior core support-separators that define a clearancechannel through which conductors or optical fibers may be disposed.

BACKGROUND OF THE INVENTION

Many communication systems utilize high performance cables normallyhaving four pairs or more that typically consist of two twisted pairstransmitting data and two receiving data as well as the possibility offour or more pairs multiplexing in both directions. A twisted pair is apair of conductors twisted about each other. A transmitting twisted pairand a receiving twisted pair often form a subgroup in a cable havingfour twisted pairs. High-speed data communications media in currentusage include pairs of wire twisted together to form a balancedtransmission line. Optical fiber cables may include such twisted pairsor replace them altogether with optical transmission media (fiberoptics).

When twisted pairs are closely placed, such as in a communicationscable, electrical energy may be transferred from one pair of a cable toanother. Energy transferred between conductor pairs is undesirable andreferred to as crosstalk. The Telecommunications Industry Associationand Electronic Industries Alliance have defined standards for crosstalk,including TIA/EIA-568-B.2-1 for Category 5e and Category 6. TheInternational Electrotechnical Commission has also defined standards fordata communication cable crosstalk, including ISO/IEC 11801. Onehigh-performance standard for 100 MHz cable is ISO/IEC 11801, Category5. Additionally, more stringent standards are being implemented forhigher frequency cables including Category 6 and Category 7, whichincludes frequencies of 200 and 600 MHz, respectively. Transmissionrates of as much as 10 G-base-T employing 10 Gigabit Ethernet overcopper at frequencies of 650 MHz or higher are now either anticipated orincluded as new industry standards emerge. Industry standards, cablespecifications, and known commercially available products are listed inTable 1. TABLE 1 Industry Standard Cable Specifications ANIXTER ANIXTERXP6 XP7 ALL DATA AT TIA TIA R3.00XP R3.00XP 100 MHz CAT 5e CAT 6 11/0011/00 MAX TEST  100 MHz  250 MHz  250 MHz  350 MHz FREQUENCY MAX 22.0 dB19.8 dB 21.7 dB 19.7 dB ATTENUATION MIN POWER 32.3 dB 42.3 dB 34.3 dB44.3 dB SUM NEXT MIN 13.3 dB 24.5 dB ACR MIN POWER 10.3 dB 22.5 dB 12.6dB 23.6 dB SUM ACR MIN POWER 20.8 dB 24.8 dB 23.8 dB 25.8 dB SUM ELFEXTMIN RETURN 20.1 dB 20.1 dB 21.5 dB 22.5 dB LOSSNote:Anixter recommends XP6 for Ethernet and Fast Ethernet applications, XP6or XP7 for ATM applications, and XP7 for Gigabit Ethernet.

In conventional cable, each twisted pair of conductors for a cable has aspecified distance between twists along the longitudinal direction. Thatdistance is referred to as the pair lay. When adjacent twisted pairshave the same pair lay and/or twist direction, they tend to lie within acable more closely spaced than when they have different pair lays and/ortwist direction. Such close spacing increases the amount of undesirablecross-talk that occurs. Therefore, in many conventional cables, eachtwisted pair within the cable has a unique pair lay in order to increasethe spacing between pairs and thereby to reduce the cross-talk betweentwisted pairs of a cable. Twist direction may also be varied. Along withvarying pair lays and twist directions, individual solid metal or wovenmetal air shields, i.e. aluminum laminated to polyethylene terephthalate(PET) shields and/or woven metal such as braid shields, can be used toelectro-magnetically isolate pairs from each other or isolate the pairsfrom the cable jacket and the surrounding environment. Shielded cable,although exhibiting better cross-talk isolation, is more difficult, timeconsuming and costly to manufacture, install, and terminate.Individually shielded pairs must generally be terminated using specialtools, devices and techniques adapted for the job, also increasing costand difficulty.

One popular cable type meeting the above specifications is UnshieldedTwisted Pair (UTP) cable. Because it does not include shielded pairs,UTP is preferred by installers and others associated with wiringbuilding premises, as it is easily installed and terminated. However,UTP fails to achieve superior cross-talk isolation such as required bythe evolving higher frequency standards for data and other state of theart transmission cable systems, even when varying pair lays are used.

Some cables have used supports in connection with twisted pairs. Thesecables, however, suggest using a standard “X”, or “+” shaped support,hereinafter both referred to as the “X” support. Protrusions may extendfrom the standard “X” support. The protrusions of these prior inventionshave exhibited substantially parallel sides.

The document, U.S. Pat. No. 3,819,443, to Sun Chemical Corporation,hereby incorporated by reference, describes a shielding membercomprising laminated strips of metal and plastics material that are cut,bent, and assembled together to define radial branches on said member.It also describes a cable including a set of conductors arranged inpairs, said shielding member and an insulative outer sheath around theset of conductors. In this cable the shielding member with the radialbranches compartmentalizes the interior of the cable. The various pairsof the cable are therefore separated from each other, but each is onlypartially shielded, which is not so effective as shielding around eachpair and is not always satisfactory.

The solution to the problem of twisted pairs lying too closely togetherwithin a cable is embodied in three U.S. Pat. No. 6,150,612 toPrestolite, U.S. Pat. No. 5,952,615 to Filotex, and U.S. Pat. No.5,969,295 to CommScope incorporated by reference herein, as well as anearlier similar design of a cable manufactured by Belden Wire & CableCompany as product number 1711A. The prongs or splines in the Beldencable provide superior crush resistance to the protrusions of thestandard “X” support. The superior crush resistance better preserves thegeometry of the pairs relatives to each other and of the pairs relativeto the other parts of the cables such as the shield. In addition, theprongs or splines in this invention preferably have a pointed orslightly rounded apex top which easily accommodates an overall shield.These cables include four or more twisted pair media radially disposedabout a “+”-shaped core. Each twisted pair nests between two fins of the“+”-shaped core, being separated from adjacent twisted pairs by thecore. This helps reduce and stabilize crosstalk between the twisted pairmedia. U.S. Pat. No. 5,789,711 to Belden describes a “star” separatorthat accomplishes much of what has been described above and is alsoherein incorporated by reference.

However, these core types can add substantial cost to the cable, as wellas excess material mass which forms a potential fire hazard, asexplained below, while achieving a crosstalk reduction of typically 3 dBor more. This crosstalk value is based on a cable comprised of afluorinated ethylene-propylene (FEP) conductors with low smoke PVCjackets as well as cables constructed of FEP, PVDF, and ECTFE jacketswith FEP insulated conductors for meeting NFPA 262 plenum applicationsfor fire retardant and smoke suppression requirements. For riserapplications (i.e. UL 1666, etc.), properly PVC jackets with polyolefinconductors are useful for meeting the U.S. standards, however, globallythe need for halogen free jackets continues.

Cables where no separation between pairs exist will exhibit lessdesirable cross-talk values. When pairs are allowed to shift based on“free space” within the confines of the cable jacket, the fact that thepairs may “float” within a free space can reduce overall attenuationvalues due to the ability to use a larger conductor to maintain 100 ohmimpedance. The movement occurs when the cable is put on new reels or ona reelex box during installation and stress on the conductor may causeelectrical degradation. As the jacket proximity to the conductors isfurther removed, the electrical properties between conductors orconductor pairs may also improve. FIG. 8B is an example of the presentinvention which assists greatly in providing further separation of thecable jacket from individual or paired conductors. The trade-off withallowing the pairs to float is that the pair of conductors tend toseparate slightly and randomly. This undesirable separation contributesto increased structural return loss (SRL) and more variation inimpedance.

One method to overcome this undesirable trait is to twist the conductorpairs with a very tight lay. This method has been proven impracticalbecause such tight lays are expensive and greatly limit the cablemanufacturer's throughput and overall production yield. An improvementincluded by the present invention to structural return loss and improvedattenuation is to provide a central circular ring region with variousextending protrusions for pair separation.

The central ring portion can optionally include a hollow region to actas a hollow duct which is available for the future filling with opticalfiber or coaxial cable or twisted pair conductors. Inside the centralring portion it is possible to have a second inner section that includeseither a smooth or rifled surface as needed for blown finerapplications. The fiber optic portions may be blown by gaseous means(normally air) or pulled into the hollow region with a pull tape. Thefiber optics may be installed in the hollow duct in advance of theinsertion of conductor pairs and an overall jacket. Also, future fillingof the hollow ducts may occur with any of the communications media(fiber, coax, twisted pair, etc.). This ability to “future fill” givesthe cable additional “dual” functionality and addresses the concern thatinstallers share regarding the need to remove or add new wire and cableto existing plenum or non-plenum areas carrying older media.

Other improvements have been shown and filed in U.S. application US2003/0037955/A1 filed at the United States Patent and Trademark Officeon Aug. 25, 2001 and published Feb. 27, 2003 and subsequent PCTinternational publication number WO 03/021607 A1, filed May 1, 2002 andpublished 13 Mar. 2003.

Another improvement, and one that is included by the present invention,is to provide a circular ring region which is surrounded by roundedlobes in a symmetric diamond-like geometry that defines as many as fourseparate regions for pair separation and derivatives thereof. Again thecentral ring portion can optionally include a hollow region to act as anair blown fiber (ABF) duct which is available for filling with opticalfiber or for the aforementioned coaxial or twisted pair applications.

A third improvement included by the present invention is to provide ahollow four-petal or “daisy” shaped arrangement with a central core thatmay or may not be hollow, and derivatives thereof—again to allow forpair separation. Individual or paired conductors are placed within thehollow petals as required depending on electrical, mechanical, andflammability design requirements. If the central region is hollow, thepossibility again exists for that region to act as an air blown fiber(ABF) duct which is available for filling with optical fiber.

Still another improvement included by the present invention is toprovide cross-like arrangement of varying geometric design andderivatives thereof. One such arrangement is a more conventionalcross-like separator section with “rifled” sections extending outwardinto four quadrants away from the central region. This rifled cross isthen encased within an outer insulated layer which is itself shaped inan identical cross except that the dimensions of this outer cross islarger than the rifled inner cross and functions as a “skin”. In thismanner the separator uses less material than a conventional crossseparator and thus reduces the BTU content within a jacketed (or even anunjacketed) cable. An optimal design that meets the stringent fireretardancy and smoke suppression requirements as well as the electricalneeds, includes the use of an outer solid skin of either FEP or PVCsufficient to reduce flame and smoke over a foamed insulation materialwith a very low (nearer to 1.00 the better) dielectric constant. To passrecent CMP-50 requirements, lower fuel loads are very helpful. To reducefuel loads, the addition of air and reduction of material are bothuseful methods for achieving the desired goals of improved flammability,smoke generation, and electrical properties of any cable constructionusing separators of the present invention. Dual extrusion is a commonlyknown method that can allow for a dual insulation design capable ofproviding such a product. Dual extrusion also allows for moresophisticated designs where lowering BTU content is important, as forexample in the IEC C332-3B₁ and B₂ test protocols for Europeanapplications as part of the specifications listed in Table 2. Use of apull tape within these constructions, the tape itself constructed fromfire retardant, smoke reducing materials, is also part of the presentinvention and provides another avenue to meet the needs of upgradingexisting cable installations when new internal communications media mustbe provided. TABLE 2 European Flammability Specifications Class TestMethods Classification Criteria (1) Additional Classification Ac EN ISO1716 PCS ≦ 2.0 MJ.kg-1 (2) — Blc EN 50266-2-x (3) FS ≦ 1.75 m; and Smokeproduction (5) and And THR600s ≦ 7.5 MJ; and Flaming droplets/particles(6); Peak RHR ≦ 15 kW; and And FIGRA ≦ 120** W · s-1 Acidity/Corrosivity(7) EN 50265-2-1 H ≦ 425 mm B2c EN 50266-2-x (3) FS ≦ 2.00 m; and Smokeproduction (5) and And THR600s ≦ 15 MJ; and Flaming droplets/particles(6); Peak RHR ≦ 50 kW; and And FIGRA ≦ 150** W · s-1 Acidity/Corrosivity(7) EN 50265-2-1 H ≦ 425 mm Clc EN 50266-2-y (4) FS ≦ 2.0 m; and Smokeproduction (5) and 600s THR600s ≦ 15 MJ; and Flaming droplets/particles(6); And Peak RHR ≦ 50 kW; and And FIGRA ≦ 150** W · s-1Acidity/Corrosivity (7) EN 50265-2-1 H ≦ 425 mm C2c EN 50266-2-y (4) FS≦ 2.5 m; and Smoke production (5) and 600s THR600s ≦ 35 MJ; and Flamingdroplets/particles (6); And Peak RHR ≦ 100 kW; and And FIGRA ≦ 250** W ·s-1 Acidity/Corrosivity (7) EN 50265-2-1 H ≦ 425 mm Dc EN 50265-2-1 H ≦425 mm Flaming droplets/particles (6); And Acidity/Corrosivity (7) Ec Noperformance determined**provisional figures

Yet another improvement included by the present invention is to providevariations on the cross-like arrangement by adding “zig-zag” with andwithout “sickle-like” endings regions instead of “rifled” sectionsextending outward into four quadrants away from the central region.

For all these configurations, a major purpose of the inventive design ofthese separators is to provide contributions to improved attenuation,power sum NEXT (near end cross talk), power sum ACR (attenuationcross-talk ratio) and ELFEXT (equal level far end cross-talk) byproviding for better control of spacing of the pairs, adding moreair-space, and allowing for “pair-twinning” at different lengths.Additional benefits include reduction of the overall material massrequired for conventional spacers, which greatly contributes to flameand smoke reduction. The other major purpose is to allow for “future” orconcurrent filling of any media such as optical, twisted pair, or coaxconductors with sufficient spacing so that electrical and opticalintegrity is maintained.

In recent years, electro-optical equipment has begun to replaceelectronic equipment for certain applications, such as telecommunicationand data communication networks. This trend should continue because theelectro-optical equipment has inherent advantages over purely electronicequipment. These advantages include a broader bandwidth for signaltransmission, greater storage capability for data, and inherent immunityto electromagnetic interference. Given these advantages ofelectro-optical equipment, fiber optic cables have become increasinglyimportant because they transmit information and signals between thevarious pieces of electro-optical equipment.

The appearance of these cables resembles electrical cables, but fiberoptic cables are smaller in size and lighter in weight. Fiber opticcables comprise optical fibers and other cable elements which areprotected from the external environment by an external jacketing. Thesecables may be of a traditional design with the fibers surrounded bystrength members and protective elements in the cable core or of a morenon-traditional, loosely-bundled type with the fibers contained looselywithin tubes or ducts in a cable core.

According to U.S. Pat. No. 4,997,256, optical fiber units may besuitable for installation by the force of a fluid flowing through apassage. The unit, in this case, includes at least one optical fiber andat least one interstitial cord. The fibers and cords are of the samediameter. They are bundled and surrounded by a first sheath that isformed of a material having a high Young's modulus. An outer sheath, offoamed polyethelene may surround the first sheath. More particularly,the invention described includes an improvement in the blowing andtransmission properties of such an optical fiber unit.

The objects of the invention can be achieved by an optical fiber unit ofa type that is to be installed by the drag force of a pressure fluidflowing through a pipe, containing at least one optical fiber and morethan one interstitial cord which are bundled and surrounded by an innerand outer sheathing to provide a unitary assembly, which inner sheath ismade of a resin that has a high Young's modulus and that exhibits smallresidual strain during the application of sheathing. The outer sheath ismade of a foamed polyethylene.

Another object of this invention can be attained in an effective way ifthe interstitial cord used in the optical fiber unit has substantiallythe same outside diameter as the optical fiber. Further, the object ofthis invention can be attained in a more effective way if at least oneof the interstitial cords has a sufficient strength to work as a ripcord that assists in ripping away the inner and outer sheaths when theoptical fiber is withdrawn from the optical fiber unit during endpreparations.

In the case of the present invention, the central “hollow” portion ofthe support-separator can act as the duct for accommodating theinventive entity described. The duct could be composed of polybutyleneterephthalate, amorphous nylon or other suitable materials such asdescribed in the U.S. Pat. No. 4,997,256 patent. Essentially all otheraspects of the '256 patent which include installing optical fiber intopredisposed duct can be incorporated into the present invention usingthe central hollow portions of the support separator as the predisposedduct.

U.S. Pat. No. 6,173,107 describes a method and apparatus for installingor advancing a lightweight and flexible transmission line along atubular pathway comprising insertion of the free end of such a line intoa previously installed pathway, and propelling the line along thepathway by fluid drag of a gaseous medium passed through the pathway inthe desired direction of advance. The present invention may alsoincorporate this method and potentially the apparatus as described belowfor the same purpose utilizing the central core of thesupport-separators for ABF or pulling with a pull tape.

It should be appreciated that to generate sufficient fluid drag topropel the transmission line, the gaseous medium has to be passedthrough the pathway with a flow velocity much higher than the desiredrate of advance.

The terms “lightweight and flexible” with respect to the transmissionline are to be understood as meaning “sufficiently lightweight andflexible” for the transmission line to be propelled by the fluid drag.The flow velocity of the gaseous medium may be steady or may be suitablyvaried, for example either between a first velocity producing no, orinsufficient, fluid drag to propel the fiber or wire member, and asecond velocity producing sufficient fluid drag to propel the fiber orwire member, or between a first and second velocity both producingsufficient fluid drag for propelling the fiber or wire member.Conveniently the variations in velocity take the form of repeated abruptchanges between the first and second velocity. The aforementionedvariations in flow velocity may include periods during which the flow isreversed with respect to the desired direction of advance of thetransmission line.

It is to be understood that more than one transmission line may bepropelled along the same tubular pathway.

A transmission line may, for example, comprise a single optical fiber orwire, protected by at least a primary coating but preferably containedwithin an outer envelope. Alternatively, a fiber or wire member maycomprise a plurality of optical fibers or wires contained within acommon envelope. The envelope may loosely or tightly surround the fiber(wire), or fibers (wires).

The method may be used for insertion of an optical fiber or wire memberinto, or its withdrawal from, the pathway.

The gaseous medium is chosen to be compatible with the environment inwhich the invention is performed, and in ordinary environments will be anon-hazardous gas or gas mixture. With the proviso about compatibilitywith the environment, the gaseous medium is preferably air or nitrogen.

The tubular pathways and/or the fiber or wire members are convenientlybut not necessarily of circular cross-section, and the fiber or wiremember is always smaller than the pathway.

In practice, when installing an optical fiber member, the pathwayinternal diameter will generally be greater, and frequently much greaterthan 1 mm, and the external diameter of the fiber member greater than0.5 microns.

A preferred range of diameters for the pathway is 1 to 10 mm,conveniently between 3 and 7 mm, and a preferred range of diameters forthe fiber members is 1 to 4 mm, although much larger diameters may beused provided the fiber member is sufficiently lightweight and flexible.The diameter of the fiber member or members is preferably chosen to begreater than one tenth, and conveniently to be about one half of thepathway diameter or greater (and appropriately less, of course, if morethan one fiber member is to be propelled through the same pathway). Forsingle mode fiber the fiber and cladding diameter range is normally from7-250 microns and for multimode fiber the range is normally between 250and 900 microns.

Insertion of a fiber (or wire) member by means of the fluid drag of agas passing over the fiber member has several advantages over methodsinvolving pulling an optical fiber (wire) cable with a pull cord.

Firstly, the extra step of providing a pull cord or flat pull tape witha Kellum-like grip is eliminated.

Secondly, using the fluid drag of a gaseous medium produces adistributed pulling force on the fiber (wire) member. This isparticularly advantageous if the installation route contains one or morebends. If, as would be the case with a pulling cord, the pulling forcewere concentrated at the leading end of the fiber member, any deviationof the pathway from a straight line would greatly increase frictionbetween the fiber member and the internal walls of the pathway, and onlya few bends would be sufficient to cause locking of the fiber. Thedistributed pulling force produced by the fluid drag, on the other hand,enables bends to be negotiated fairly easily, and the number of bends ina given installation is no longer of much significance.

Thirdly, the fluid drag substantially reduces overall pulling stress onthe fiber (or wire) member and so permits the fiber (or wire) member tobe of relatively simple and cheap construction.

Furthermore, because the fiber member is not subjected to anysubstantial pulling stress during installation, little allowance, ifany, needs to be made for subsequent relaxation. According to a furtheraspect of the invention described in U.S. Pat. No. 6,173,107, a methodof installing a transmission line comprises installing a conduit havingone or more ductlets providing tubular pathways. The ductlets describedbelow, for the present invention, may be the central hollow regions ofany shape associated with the support-separators described.

The communications route may be initially designed and upgradedaccording to a customer's needs or desires. For example, afterinstallation of the communications cable with support-separator, wiremembers containing one or more lightweight and flexible wires initiallymay be propelled through a pathway using fluid drag. Thereafter, theroute may be upgraded by installing further wire members and/orinserting, by the aforesaid method using fluid drag, one or more fibermembers into the associated ductlets as required. It would also bepossible to remove fiber from existing ducts and reinstall newer fiberor new conductors as needed. In some cases, it may be possible to removethe duct itself and re-install (or not depending on the need).

Installing optical fiber and/or wire transmission lines by this methodhas several advantages over conventional techniques.

First, since the conduit is installed without containing any opticalfibers, conventional rope pulling and similar techniques may be freelyemployed for installing the conduit. Second, the capacity can readily beadapted to requirements. Thus, while initially only one or two fiber orwire members may be sufficient to carry the traffic, multiple cables maycontain a much larger number of ductlets than are required at the timeof installation, and further fiber or other members may be insertedlater on as and when needed. The support-separator of the presentinvention is cheap compared to the cost of the fibers, and spareductlets to accommodate further fibers and/or wires as and when extracapacity is required can thus be readily incorporated without addingmore than a small fraction to overall costs.

The method of the U.S. Pat. No. 6,173,107 invention also permits theinstallation of improved later generations of transmission lines. It ispossible, for example, to install at first one or more fiber membersincorporating multimode fibers, and at a later date add, or replace theinstalled multimode fiber members with fiber members incorporatingmonomode fibers. Installed fiber members may conveniently be withdrawnfrom the ductlet, and replacement fiber members be inserted by using theaforesaid method of propelling by fluid drag of a gaseous medium.

Alternatively, the support-separators may comprise a plurality ofindividual tubes enveloped by a common outer sheath.

It will be appreciated that the present invention largely avoids therisk, inherent in handling optical fiber cables with a large number offibers, of accidentally damaging before or during installation in asingle event a large number of expensive optical fibers.

The present invention also enables the installation of continuousoptical fibers over several installation lengths without joints.

Furthermore, individual fiber members routed through the conduit can berouted, without requiring fiber joints, into different branches of theconduits at various junction points.

Finally, a unique construction of the blown fiber duct or ductlets isdescribed in WO patent application 01/34366 entitled: “Flexible plasticTubing Construction Having a Sight Glass Window.”

Accordingly, the tubing construction of the invention herein involved isparticularly adapted for use in ABF applications and other cable or wireinstallations wherein the ability to view the cables or wires within thetubing is desired for installation, servicing, or administration. It ispossible that the present invention could incorporate the principals ofthe 01/34366 invention as well.

In another illustrative embodiment of the 01/34366 invention, the tubing(or in the case of the present invention—the lining of the inner centralhollow core extending along the length of the support-separator)includes a third sidewall segment formed integrally with the first andsecond segments as having inner surface, which defines a portion oftubing innermost surface. Such inner surface may be profiled as defininga series of radially-disposed longitudinal splines, ribs, or otherprojections. With respect to ABF installation, such projections havebeen observed to reduce surface area contact between the cable andtubing sidewall, which results in corresponding decreased friction asthe cable is blown through the tubing. Such projections also develop alower velocity boundary layer in the gas flow near the surface which hasthe tendency to direct the fiber into the higher velocity flow towardsthe center of the tubing. The end result is less drag on the tubingwhich facilitates long runs and direction changes such as around bends.

Advantages of the 01/34366 invention include a flexible plastic tubingconstruction which is provided as having a sight-glass capabilitywithout affecting the gross fire resistance, electrical conductivity, orother specified chemical without affecting the gross fire resistance,electrical conductivity, or other specified chemical or physicalproperties of the tubing. Additional advantages include a tubingconstruction which is economical to manufacture in long, continuouslengths, and which further is particularly adapted for use in ABFinstallations. These and other advantages will be readily apparent tothose skilled in the art based upon the disclosure contained herein.

As described above, an additional purpose of the present invention is toform and allow the central hollow region of the support separatorspacers of the communications cables to act as a duct for ABF in theevent this is desirable for installation purposes. The materials used toconstruct the support separators can be solid, semi-solid, foamed,foamed with a solid skin, or hollow. The lining of the central hollowregion can be composed of polybutylene terephthalate (PBT) or otherknown materials capable of providing a sufficient combination oflubricity and friction to ensure proper accommodation of blown fiber“post” installation. There may be a separate inner lining within thecentral ring portion and it is always possible that the inner lining canbe used such as shown in FIG. 1B.

Many precautions are taken to resist the spread of flame and thegeneration of and spread of smoke throughout a building in case of anoutbreak of fire. Clearly, cables must be designed to protect againstloss of life and also minimize the costs of a fire due to thedestruction of electrical and other equipment. Therefore, wires andcables for building installations are required to comply with thevarious flammability requirements of the National Electrical Code (NEC)in the U.S. as well as International Electrotechnical Commission (EIC)and/or the Canadian Electrical Code (CEC).

Cables intended for installation in the air handling spaces (i.e.plenums, ducts, etc.) of buildings are specifically required byNEC/CEC/IEC to pass the flame test specified by UnderwritersLaboratories Inc. (UL), UL-910, or its Canadian Standards Association(CSA) equivalent, the FT6. The UL-910 and the FT6 represent the top ofthe fire rating hierarchy established by the NEC and CEC respectively.Also important are the UL 1666 Riser test and the IEC 60332-3C and Dflammability criteria. Cables possessing these ratings, genericallyknown as “plenum” or “plenum rated” or “riser” or “riser rated”, may besubstituted for cables having a lower rating (i.e. CMR, CM, CMX, FT4,FTI or their equivalents), while lower rated cables may not be usedwhere plenum or riser rated cables are required. Future ratings includethe CMP-50 standard which is considered to the European requirement ofthe future.

Cables conforming to NEC/CEC/IEC requirements are characterized aspossessing superior resistance to ignitability, greater resistance tocontribute to flame spread and generate lower levels of smoke duringfires than cables having lower fire ratings. Often these properties canbe anticipated by the use of measuring a Limiting Oxygen Index (LOI) forspecific materials used to construct the cable. Conventional designs ofdata grade telecommunication cable for installations in plenum chambershave a low smoke generating jacket material, e.g. of a specially filledPVC formulation or a fluoropolymer material, surrounding a core oftwisted conductor pairs, each conductor individually insulated with afluorinated insulation layer. Cable produced as described abovesatisfies recognized plenum test requirements such as the “peak smoke”and “average smoke” requirements of the Underwriters Laboratories, Inc.,UL910 Steiner tunnel test and/or Canadian Standards Association CSA-FT6(Plenum Flame Test) while also achieving desired electrical performancein accordance with EIA/TIA-568A for high frequency signal transmission.

While the above described conventional cable, including the Belden 1711Acable design, due in part to their use of fluorinated polymers, meetsall of the above design criteria, the use of fluorinated polymers isextremely expensive and may account for up to 60% of the cost of a cabledesigned for plenum usage. A solid core of these communications cablescontributes a large volume of fuel to a potential cable fire. Formingthe core of a fire resistant material, such as with FEP (fluorinatedethylene-propylene), is very costly due to the volume of material usedin the core, but it should help reduce flame spread over the 20 minutetest period. Reducing the mass of material by redesigning the core andseparators within the core is another method of reducing fuel andthereby reducing smoke generation and flame spread. For the commercialmarket in Europe, low smoke fire retardant polyolefin materials havebeen developed that will pass the EN (European Norm) 502666-Z-X Class Brelative to flame spread, total heat release, related heat release, andfire growth rate. Prior to this inventive development, standard cableconstructions requiring the use of the aforementioned expensivefluorinated polymers, such as FEP, would be needed to pass this rigoroustest. Using low smoke fire retardant polyolefins or foamed low smokesemi-rigid PVC for specially designed separators used in cables thatmeet the more stringent electrical requirements for Categories 6 and 7and also pass the new norm for flammability and smoke generation is alsoa further subject of the present invention.

Solid flame retardant/smoke suppressed polyolefins may also be used inconnection with fluorinated polymers. Commercially available solid flameretardant/smoke suppressed polyolefin compounds all possess dielectricproperties inferior to that of FEP and similar fluorinated polymers. Inaddition, they also exhibit inferior resistance to burning and generallyproduce more smoke than FEP under burning conditions. A combination ofthe two different polymer types can reduce costs while minimallysacrificing physio-chemical properties. An additional method that hasbeen used to improve both electrical and flammability propertiesincludes the irradiation of certain polymers that lend themselves tocrosslinking. Certain polyolefins are currently in development that haveproven capable of replacing fluoropolymers for passing these samestringent smoke and flammability tests for cable separators, also knownas “cross-webs”. Dual insulation designs as previously mentioned arealso useful in this application. Additional advantages with thepolyolefins are reduction in cost and toxicity effects as measuredduring and after combustion.

Current separator designs must also meet the UL 910 flame and smokecriteria using both fluorinated and non-fluorinated jackets as well asfluorinated and non-fluorinated insulation materials for the conductorsof these cable constructions. In Europe, the trend continues to be useof halogen free insulation for all components, which also must meetstringent flammability regulations. The test in Europe which the presentinventive separators and subsequent cables should also pass is known as“B-1”.

A high performance communications data cable utilizing twisted pairtechnology must meet exacting specification with regard to data speed,electrical, as well as flammability and smoke characteristics. Theelectrical characteristics include specifically the ability to controlimpedance, near-end cross-talk (NEXT), ACR (attenuation cross-talkratio) and shield transfer impedance. A method used for twisted pairdata cables that has been tried to meet the electrical characteristics,such as controlled NEXT, is by utilizing individually shielded twistedpairs (ISTP). These shields insulate each pair from NEXT. Data cableshave also used very complex lay techniques to cancel E and B (electricand magnetic fields) to control NEXT. In addition, previouslymanufactured data cables have been designed to meet ACR requirements byutilizing very low dielectric constant insulation materials. Use of theabove techniques to control electrical characteristics have inherentproblems that have lead to various cable methods and designs to overcomethese problems.

Recently, the development of “high-end” electrical properties forCategory 6 and 7 cables has increased the need to determine and includepower sum NEXT (near end crosstalk) and power sum ELFEXT (equal levelfar end crosstalk) considerations along with attenuation, impedance, andACR values. These developments have necessitated the development of morehighly evolved separators that can provide offsetting of the electricalconductor pairs so that the lessor performing electrical pairs can befurther separated from other pairs within the overall cableconstruction.

Recent and proposed cable standards are increasing cable maximumfrequencies from 100-200 MHz to 250-700 MHz. In the case of the presentinvention, the intention is to meet design criteria so that theconductors are capable of carrying signals at or above 10 GHz. Themaximum upper frequency of a cable is that frequency at which the ACR(attenuation/cross-talk ratio) is essentially equal to 1. Sinceattenuation increases with frequency and cross-talk decreases withfrequency, the cable designer must be innovative in designing a cablewith sufficiently high cross-talk. This is especially true since manyconventional design concepts, fillers, and spacers may not providesufficient cross-talk at the higher frequencies.

Individual shielding is costly and complex to process. Individualshielding is highly susceptible to geometric instability duringprocessing and use. In addition, the ground plane of individual shields,3600 in ISTP's—individually shielded twisted pairs—is also an expensiveprocess. Lay techniques and the associated multi-shaped anvils of thepresent invention to achieve such lay geometries are also complex,costly and susceptible to instability during processing and use. Anotherproblem with many data cables is their susceptibility to deformationduring manufacture, installation, and use. Deformation of the cablegeometry, such as the shield, also potentially severely reduces theelectrical and optical consistency. The “cross-web” designs currently inuse provide primarily an unshielded pair, but it increases EMI/RFIshielding effectiveness, the present invention includes the use of“shielded cross-webs”. The cross-web design allows for separation thatbenefits electrical properties allowing for proper spacing betweenconductors whereas shielding of the entire cable using a shieldingbarrier between the separator and a jacket allows for overall shieldingeffectiveness especially from exterior EMIIRFI sources.

Optical fiber cables exhibits a separate set of needs that includeweight reduction (of the overall cable), optical functionality withoutchange in optical properties and mechanical integrity to prevent damageto glass fibers. For multi-media cable, i.e. cable that contains bothmetal conductors and optical fibers, the set of criteria is oftenincompatible. The use of the present invention, however, renders theseoften divergent set of criteria compatible. Specifically, optical fibersmust have sufficient volume in which the buffering and jacketing plenummaterials (FEP and the like) covering the inner glass fibers can expandand contract over a broad temperature range without restriction, forexample −40 C to 80 C experienced during shipping. It has been shown bythat cyclical compression and expansion directly contacting the bufferedglass fiber causes excess attenuation light loss (as measured in dB) inthe glass fiber. The design of the present invention allows fordesignation and placement of optical fibers in clearance channelsprovided by the support-separator. It would also be possible to placeboth glass fiber and metal conductors in the same designated clearancechannel if such a design is required. In either case the forced spacingand separation from the cable jacket (or absence of a cable jacket)would eliminate the undesirable set of cyclical forces that cause excessattenuation light loss. In addition, fragile optical fibers aresusceptible to mechanical damage without crush resistant members (inaddition to conventional jacketing). The present invention alsoaddresses this problem and allows for “air” blown fiber ducts forinstallation of fiber optics at a later time in existing installations.Here “air” refers to any gas that can be used to convey fiber down theduct (or “tube”—an empty or hollow section of the separator).

The need to continue improving cable and cable separator designs byreducing costs and improving mechanical and electrical properties aswell as flammability continues to exist.

SUMMARY OF THE INVENTION

This invention provides a lower cost communications cable and/or asupport separator for the communications cable exhibiting improvedelectrical, flammability, and optionally, optical properties. The cableor separator or cable with one or more separators have interiorsupport(s) extending along the longitudinal length of the communicationscable. The interior support has a central region extending along thelongitudinal length of the interior support. In a preferredconfiguration, the cable includes a geometrically symmetrical core witha central circular ring region with various extending protrusions forpair separation and derivatives thereof The central ring portion canoptionally include a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber.

In the present invention it is also desirable to provide a circular ringregion which is surrounded by rounded lobes in a symmetric diamond-likegeometry and derivatives thereof that define as many as four separateregions for pairs that are properly separated in the final (oftenjacketed) cable design. Again the central ring portion can optionallyinclude a hollow region to act as an air blown fiber (ABF) duct which isavailable for filling with optical fiber.

A third embodiment of the present invention provides a hollow four-petalor “daisy” shaped arrangement with a central core that may or may not behollow and derivatives thereof—again to allow for pair separation.Individual or paired conductors are placed within the hollow petals asrequired depending on electrical, mechanical, and flammability designrequirements. If the central region is hollow, the possibility againexists for that region to act as an air blown fiber (ABF) duct which isavailable for filling with optical fiber.

Still another embodiment of the present invention is to provide across-like arrangement of varying geometric designs and derivativesthereof. One such arrangement is a more conventional cross-likeseparator section with “rifled” sections extending outward into fourquadrants away from the central region. This rifled cross is thenencased or covered within an outer insulated layer which is itselfshaped in an identical cross except that the dimensions of this outercross is larger than the rifled inner cross and functions as a “skin”.In this manner the separator uses less material than a conventionalcross separator and thus reduces the BTU content within a jacketed (oreven an unjacketed) cable.

Yet another embodiment includes providing variations on the cross-likearrangement by adding “zig-zag” with and without “sickle-like” endingsregions instead of the “rifled” sections extending outward into fourquadrants away from the central region as described above.

The core support-separator is optionally foamed, semi-solid, solid skinover foam or hollow and has an optional hollow center. The rifled crossseparator profiles with ladder-like “step-sections” are similar tostandard “X” supports with the major difference that they include stepsections that lie under a solid insulation along the radially extendingportions of the support. This provides for a hollow-cross-like supportseparator that includes less overall material weight, thereby reducingpotential BTU content and thus reduces the risk of flame spread in afire scenario.

These various shaped sections of the core support-separator may behelixed as the core extends along the length of the communicationscable. Each of the adjacent shaped sections defines a clearance orclearance channel which extends along the longitudinal length of themulti-anvil shaped core support-separator. The clearance provides achannel for each of the conductors/optical fibers or conductor pairsused within the cable. The clearance channels formed by the variousshaped core support-separators extend along the same length of thecentral portion. The channels are either semi-circular, fully circular,or stepped in a circular-like manner shaped cross-section withcompletely closed surfaces in the radial direction toward the centerportion of the core and optionally opened or closed surfaces at theouter radial portion of the same core. Adjacent channels are separatedfrom each other to provide a chamber for at least a pair of conductorsor an optical fiber or optical fibers.

Additionally, to provide a duct for ABF, the central regions of theseparators can be hollow to allow for “post installation” of opticalfibers.

The various shaped core support-separators of this invention provides asuperior crush resistance to the protrusions of the standard “X” orother similar supports. A superior crush resistance is obtained by thecircular and arch-like design for separators that provide clearancechannels for additional support to the outer section of the cable. Thevarious shaped cores better preserves the geometry of the pairs relativeto each other and of the pairs relative to the other parts of thecables, such as the possible use of a shield or optical fibers. Thecircular shape provides an exterior surface that essentially establishesthe desired roundness for cable manufacturers. The exterior roundnessensures ease of die development and eventual extrusion. The roundedsurface of the core also allows for easy accommodation of an overallexternal shield.

The four-pedal or daisy shape separator sections provide similar crushresistance to the standard “X” supports with the additional feature thatthe center portion of the separator may have hollow sections for the useblown finer ducts. Additionally, these supports carry the conductorsinside hollow sections offering an additional level of mechanicalintegrity.

Additionally, the daisy shaped separator may include the use of singleor double sided PET -Aluminum film which is as much as 0.004″ (4 mil) inthickness to further provide shielding effectiveness and provide ingressof attenuated signals. It is also possible, in this geometry to includetwisted pair conductors between the individual hollow petals such thatseparation between twisted pair conductors can be accomplished in thismanner.

The conductors can be set apart in each of these unique geometries sothat individual or sets of pairs can be spaced closer or farther apartfrom one another, allowing for better power sum values of equal levelfar end and near end crosstalk. This “offsetting” between conductorpairs in a logical, methodological pattern to optimize electricalproperties is an additional benefit associated with the cross-shapedseparators that include “zig-zag” and sickle-like sections.

According to one embodiment, the cable includes a plurality oftransmission media with metal and/or optical conductors that areindividually disposed; and an optional outer jacket maintaining theplurality of data transmission media in proper position with respect tothe core. The core is comprised of a support-separator having variousshaped profiles that define a clearance to maintain spacing betweentransmission media or transmission media pairs in the finished cable.The core may be formed of a conductive or insulative material to furtherreduce cross-talk, impedance and attenuation.

Accordingly, the present invention provides for a communications cable,with specifically shaped support-separators, that meet the exactingspecifications of high performance data cables and/or fiber optics orthe possibility of including both transmission media in one cable, has asuperior resistance to deformation during manufacturing and use, allowsfor control of near-end cross-talk, controls electrical instability dueto shielding, is capable of 200 and 600 MHz (Categories 6 and 7)transmission and possibly up to or greater than 1 GHz, with a positiveattenuation to cross-talk ratio (ACR ratio) of typically 3 to 10 dB.

Moreover, the present invention provides a separator so that the jacketmaterial (which normally has inferior electrical properties as comparedwith the conductor material) is actually pushed away from the electricalconductor, thus acting to again improve electrical performance (ACR,etc.) over the life of the use of the cable. These separators, by simplegeometric considerations are also superior to the “X” type separator inthat they also increase the physical distance between the conductorpairs within the same cable configuration, as shown in FIGS. 7A and B.

Additionally, it has been known that the conductor pair may actuallyhave physical or chemical bonds that allow for the pair to remainintimately bound along the length of the cavity in which they lie. Thepresent invention describes a means by which the conductor pairs areadhered to or forced along the cavity walls by the use of grooves thatmay exist within the inner diameters of the circular ring and daisy-likegeometries. This again increases the distance, thereby increasing thevolume of air or other dielectrically superior medium between conductorsin separate cavities. As discussed above, spacing between pairs, spacingaway from jackets, and balanced spacing all have an effect on finalelectrical cable performance.

It is an object of the invention to provide a data/multi-media cablethat has a specially designed interior support that accommodatesconductors with a variety of AWG's, impedances, improved crushresistance, controlled NEXT, controlled electrical instability due toshielding, increased breaking strength, and allows the conductors, suchas twisted pairs, to be spaced in a manner to achieve positive ACRratios.

It is still another object of the invention to provide a cable that doesnot require individual shielding and that allows for the precise spacingof conductors such as twisted pairs and/or fiber optics with relativeease. In the present invention, the cable would include individual glassfibers as well as conventional metal conductors as the transmissionmedium that would be either together or separated in clearance channelchambers provided by the various shaped sections of the coresupport-separator.

Another embodiment of the invention includes having variousgeometrically shaped core support-separators with a central region thatis either solid or partially solid. This includes the use of a foamedcore and/or the use of a hollow center of the core, which in both casessignificantly reduces the material required along the length of thefinished cable. The effect of foaming and/or producing asupport-separator with a hollow center portion should result in improvedflammability of the overall cable by reducing the amount of materialavailable as fuel for the UL 910 test, improved electrical propertiesfor the individual non-optical conductors, and reduction of weight ofthe overall cable.

Additionally, the optical fibers could be present or later blown intocenter hollow core sections (where they exist) of thesupport-separators. The hollow center allows for the possible use withABF—blown fiber ducts that allow for “post-installation” of the fiber(in any form).

Yet another embodiment of the invention allows for interior corrugatedclearance channels provided by the sections of the coresupport-separators. This corrugated internal section has internal axialgrooves that allow for separation of conductor pairs from each other oreven separation of single conductors from each other as well asseparation of optical conductors from conventional metal conductors.Alternatively, the edges of said grooves may allow for separation thusproviding a method for uniformly locating or spacing the conductor pairswith respect to the channel walls instead of allowing for randomfloating of the conductor pairs.

Alternatively, depending on manufacturing capabilities, the use of atape or polymeric binding sheet(s) may be necessary in lieu of extrudedthermoplastic jacketing

Yet another related embodiment includes the use of a strength membertogether with, but outside of the core support-separator runningparallel in the longitudinal direction along the length of thecommunications cable. In a related embodiment, the strength member couldbe the core support-separator itself, or in an additional relatedembodiment, the strength member could be inserted in the hollowcenter-portion of the core in lieu of a duct or ductlet for blown fiber.

It is to be understood that each of the embodiments above could includea flame-retarded, smoke suppressant version and that each could includethe use of recycled or reground thermoplastics in an amount up to 100%.

A method of producing the communications cable, introducing any of themulti-shaped core separators as described above, into the cableassembly, is described as first passing a plurality of transmissionmedia and a core through a first die which aligns the plurality oftransmission media with surface features of the core and prevents orintentionally allows twisting motion of the core. Next, the methodbunches the aligned plurality of transmission media and core using asecond die which forces each of the plurality of the transmission mediainto contact with the surface features of the core that maintain aspatial relationship between each of a plurality of transmission media.Finally, the bunched plurality of transmission media and core areoptionally twisted to close the cable, and the closed cable may beoptionally jacketed.

Other desired embodiments, results, and novel features of the presentinvention will become more apparent from the following drawings and theaccompanying preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cross-section view of one embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation. The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 1B is a cross-section view of a second embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for either increasing lubricity or friction with fourextending rifled protrusions each extending in a preferred 90 degreeseparation from each other for optimum pair separation.

FIG. 1C is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections with four extending rifled protrusions each extendingin a preferred 90 degree separation from each other for optimum pairseparation.

FIG. 1D is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1C, but also includes the optional useof a organic or inorganic fibers including polyamide (for exampleKevlarg) filling and an optional strength member within the second innerring within the hollow region comprised of a different material than theouter ring as well as allowing for multiple separate multimode or singlemode fiber optic units also contained within the same hollow region withfour extending rifled protrusions each extending in a preferred 90degree separation from each other for optimum pair separation.

FIG. 1E is a cross-section view of a fifth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1B and also includes an inner pull tapefor attaching optical fibers or metallic conductors wherein the tapeoptionally itself incorporates a grip or for which a grip is providedfor future pulling of those communication media through the hollowregion at some future time or during an installation with four extendingrifled protrusions each extending in a preferred 90 degree separationfrom each other for optimum pair separation.

FIG. 1F is a cross-section view of a sixth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1B but also two individual conductors(which may be twisted) inside the second inner ring which is smoothinstead of rifled within the hollow region and comprised of a differentmaterial than the outer ring as well as allowing for multiple separatemultimode or single mode fiber optic units also contained within thesame hollow region with four extending rifled protrusions each extendingin a preferred 90 degree separation from each other for optimum pairseparation.

FIG. 1G is a cross-section view of a seventh embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A with four extending rifledprotrusions each extending in a preferred 90 degree separation from eachother for optimum pair separation, but also includes the optionaladdition of one or more coaxial conductors contained in the centerhollow region.

FIG. 2A is a cross-section view of an another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A but possesses 6 instead of 4 rifledprotrusions each extending in a preferred degree separation from eachother for optimum pair separation.

FIG. 2B is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner rifledring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation.

FIG. 2C is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring.

FIG. 2D is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring, Also, betweenas few as one and as many as six of the extending projections,additional daisy-like spacers (as shown in FIG. 5A) are placed whichthemselves allow for spacing of individual conductors or conductorpairs.

FIG. 2E is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlar®) filling and anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections are shownwithout the additional daisy-like spacers (FIG. 5A).

FIG. 2F is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theaddition of one or more conductors including optionally organic orinorganic fibers such as polyamide (for example Kevlarg) filling and anoptional strength member within the second inner ring. Also, between asfew as one and as many as six of the extending projections, additionalspacers comprised of a region which includes rounded lobes in asymmetric diamond-like geometry that defines as many as four separateregions for pairs that are properly separated in the final (oftenjacketed) cable design (as shown in FIG. 6A) are placed which themselvesallow for spacing of individual conductors or conductor pairs.

FIG. 3A is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 1A through 2F, each againextending in a preferred 90 degree separation from each other foroptimum pair separation. The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 3B is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 1A through 2F, each againextending in a preferred 90 degree separation from each other foroptimum pair separation and also includes a second inner ring within thehollow region comprised of a different material than the outer ring foreither increasing lubricity or friction. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 3C is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 1A through 2F, each againextending in a preferred 90 degree separation from each other foroptimum pair separation and also includes also includes a second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIGS. 3D and 3E are cross-section views of another embodiment of thecable support-separator that includes a symmetrical core with a centralcircular ring region with as few as two and as many as six extendingsmooth protrusions, each protrusion extending less than those of theseries of FIGS. 1A through 2F, each again extending in a preferredseparation from each other for optimum pair separation and also includesalso includes a an optional second inner ring within the hollow regioncomprised of a different material than the outer ring for increasingfriction utilizing rifled inner spatially arranged sections. The centralring portion optionally includes a hollow region to act as an air blownfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 3F is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with no extending protrusions that includes also anoptional second inner ring within the hollow region comprised of adifferent material than the outer ring for increasing friction utilizingrifled inner spatially arranged sections. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 4A is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending protrusions each protrusionextending less than those of FIGS. 1A through 2F and each with at leasta single cross-like section extending outward from the circular ringsection in a preferred 90 degree separation from each other for optimumpair separation. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 4B is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 1A through 2F, each again extending in a preferred90 degree separation from each other for optimum pair separation andalso includes a second inner ring within the hollow region comprised ofa different material than the outer ring for either increasing lubricityor friction. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 4C is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of Figures through 2F, each again extending in a preferred 90degree separation from each other for optimum pair separation and alsoincludes a second inner ring within the hollow region comprised of adifferent material than the outer ring for either increasing lubricityor friction. The inner portion of the hollow ring region here isoptionally filled with inorganic or organic fibers such as polyamidefiber (Kevlarg) and at least four single or multimode finer optic units.

FIGS. 4D and 4E include a cross-section view of another embodiment ofthe cable support-separator that includes a symmetrical core with acentral circular ring region with as few as two and as many as sixextending protrusions each with at least a single cross-like section,each protrusion extending less than those of FIGS. 1A through 2F, eachagain extending in a preferred separation from each other for optimumpair separation and also includes also includes an optional second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 4F includes a cross-section view of another embodiment of the cablesupport-separator includes a symmetrical core with a central circularring region with no extending protrusions that includes also an optionalsecond inner ring within the hollow region comprised of a differentmaterial than the outer ring for increasing friction utilizing rifledinner spatially arranged sections. The central ring portion optionallyincludes a hollow region to act as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 5A is a cross-section view of another embodiment of the cablesupport-separator that includes a hollow four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. If thecentral region is hollow, the possibility again exists for that regionto act as an air blown fiber (ABF) duct which is available for fillingwith optical fiber. Coaxial or twisted pair conductors may also beintroduced in that region.

FIG. 5B is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains two hollow sections for additional optical or metallicconductor media The central region is hollow allowing for thepossibility that this region may act as an air blown fiber (ABF) ductwhich is available for filling with optical fiber. Coaxial or twistedpair conductors may also be introduced in that region.

FIG. 5C is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains three hollow sections of differing diameters foradditional optical or metallic conductor media. The central region issolid.

FIG. 5D is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains three hollow sections of differing diameters foradditional optical or metallic conductor media. In this case, the centerhollow section of each petal is filled with an optical fiber unit. Thecentral region is solid or optionally hollow.

FIGS. 6A, 6B, 6C are cross-sectional views of another set of embodimentsof the cable support-separator that includes a circular ring regionwhich is surrounded by rounded lobes in a symmetric diamond-likegeometry that defines as many as four separate regions for pairs thatare properly separated in the final (often jacketed) cable design. Againthe central ring portion can optionally include a hollow region that maybe used as an air blown fiber (ABF) duct which is available for fillingwith optical fiber which is comprised of solid, semi-solid, foamed orhollow polymeric smooth internal and external surfaces. FIG. 6A has noinner ring, FIG. 6B has a smooth inner ring with optionally differentmaterial than the outer ring, and FIG. 6C has an inner ring with rifledsections. Each can optionally be used for coax or twisted pair as wellas for fiber optic conductors in advance, during, or after installation.

FIG. 6D is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes the optional addition of one or more conductors includingoptionally organic or inorganic fibers such as polyamide (for exampleKevlar®) filling and an optional strength member within the second innerring (that may or may not be rifled). Again the central ring portion canoptionally include a hollow region that may be used as an air blownfiber (ABF) duct which is available for filling with optical fiber whichis comprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 6E is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion filled with a fiber optic unit as well as fourseparated conductor pairs in each of the regions defined by thesymmetric diamond-like geometry of the cable support-separator. Againthe central ring portion can optionally include a hollow region that maybe used as an air blown fiber (ABF) duct which is available for fillingwith optical fiber which is comprised of solid, semi-solid, foamed orhollow polymeric smooth internal and external surfaces.

FIG. 6F is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion with a second inner ring portion filled with afiber optic unit or other conductors as well as four cross-likeseparators (see FIG. 7A) in each of the regions defined by the symmetricdiamond-like geometry of the cable support-separator within whichanother, up to four pairs of conductors are situated and separated bythe cross-like separator. Again the central ring portion can optionallyinclude a hollow region that may be used as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 7A is a cross-section view of another embodiment of the cablesupport-separator that includes a more conventional cross-like separatorsection with “rifled” sections extending outward into four quadrantsaway from the central region and is encased or covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross is larger than the rifled inner crossand functions as a “skin”. The inner cross-like portion may bemetallized by utilizing electroless or electrolytic plating techniquesover a thermoplastic.

FIG. 7B is a cross-section view of another embodiment of the cablesupport-separator that includes the same more conventional cross-likeseparator section as with FIG. 7A except that this separator contains ashield that extends along the horizontal axis and optionally also alongthe vertical axis or both axes within the horizontal hollow portion ofthe cross-like separator. This shield is comprised of aluminum PET filmand may be configured so that it is held within the outer cross-likeseparator. The design also allows for shielding exterior to theseparator under a jacketed cable containing the separator.

FIG. 8A is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “zig-zag” extensions that extend away from thecentral region. Again the cross-like “zig-zag” arrangement may becovered within an outer insulated layer which is itself shaped in anidentical cross except that the dimensions of this outer cross arelarger than the rifled inner cross and functions as a “skin”.

FIG. 8B is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “sickle-like” extensions that extend away from thecentral region. Again the cross-like and sickle-like sectionsarrangement may be covered within an outer insulated layer which isitself shaped in an identical cross except that the dimensions of thisouter cross are larger than the rifled inner cross and functions as a“skin”.

FIG. 9 is a cross-sectional view of another embodiment with severalhollow regions for blown fiber or any transmission media for present,future, or concurrent installations using the support-separator alone orin combination with a cable.

FIGS. 10A and 10B are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion which is surrounded by semi-rounded lobes in a symmetricstar-like geometry that defines as many as four separate regions forpairs that are properly separated in the final (often jacketed) cabledesign. Again the central ring portion can optionally include a hollowregion that may be used as an air blown fiber (ABF) duct which isavailable for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces. FIGS. 10A and 10B include views of optionally filled innerhollow regions such that each can optionally be used for coax or twistedpair as well as for fiber optic conductors (in advance, during or afterinstallation). FIG. 10A includes a view of this design including theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring (that may ormay not be rifled). FIG. 10B includes a view of this design includingthe optional addition of coaxial cable in the hollow center region.

DETAILED DESCRIPTION

The following description will further help to explain the inventivefeatures of the cable and the interior support portion of the cable.

FIG. 1A is a cross-section view of one embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (100) with four extending rifled protrusions (110,112, 114, 116) each extending in a preferred 90 degree separation fromeach other for optimum pair separation. The optimum pair separation isgained by placing pairs between the four extending rifled protrusions inregions 120, 122, 124, and 126. The central circular ring portion (100)optionally includes a hollow region (130) to act as an air blown fiber(ABF) duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 1B is a cross-section view of a second embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A, but also includes a second innerring (140) within the hollow region comprised of a different materialthan the outer ring for either increasing lubricity or friction withfour extending rifled protrusions each extending in a preferred 90degree separation from each other for optimum pair separation.

FIG. 1C is a cross-section view of a third embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A, but also includes a second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections (150) with four extending rifled protrusions eachextending in a preferred 90 degree separation from each other foroptimum pair separation.

FIG. 1D is a cross-section view of a fourth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1C, but also includes the optional useof a organic or inorganic fibers (160) including polyamide (for exampleKevlar®) filling and an optional strength member within the second innerring within the hollow region comprised of a different material than theouter ring as well as allowing for multiple separate multimode or singlemode fiber optic units (162) also contained within the same hollowregion with four extending rifled protrusions each extending in apreferred 90 degree separation from each other for optimum pairseparation.

FIG. 1E is a cross-section view of a fifth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1B and also includes an inner pull tape(170) for attaching optical fibers or metallic conductors wherein thetape optionally itself incorporates a grip or for which a grip isprovided for future pulling of those communication media through thehollow region at some future time or during an installation with fourextending rifled protrusions each extending in a preferred 90 degreeseparation from each other for optimum pair separation.

FIG. 1F is a cross-section view of a sixth embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1B but also two individual conductors(180 and 182) (which may be twisted) inside the second inner ring whichis smooth instead of rifled within the hollow region and comprised of adifferent material than the outer ring as well as allowing for multipleseparate multimode or single mode fiber optic units also containedwithin the same hollow region with four extending rifled protrusionseach extending in a preferred 90 degree separation from each other foroptimum pair separation.

FIG. 1G is a cross-section view of a seventh embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A with four extending rifledprotrusions each extending in a preferred 90 degree separation from eachother for optimum pair separation, but also includes the optionaladdition of one or more coaxial conductors (190) with a tinned copperbraided shield (192).

FIG. 2A is a cross-section view of an another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIG. 1A but possesses 6 instead of 4 rifledprotrusions (210, 212, 214, 216, 218, 220) each extending in a preferreddegree separation from each other for optimum pair separation. Theoptimum pair separation is gained by placing pairs between the sixextending rifled protrusions in regions 230, 232, 234, 236, 238, and240. The central circular ring portion (200) optionally includes ahollow region (250) to act as an air blown fiber (ABF) duct which isavailable for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 2B is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A, with as few as two and asmany as six extending protrusions each extending in a preferred degreeseparation along the outer ring from each other for optimum pairseparation, but also includes a second inner ring within the hollowregion comprised of a different material than the outer ring forincreasing friction utilizing rifled inner spatially arranged sections(260).

FIG. 2C is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section (270) with as few as two and as many as six extendingprotrusions each extending in a preferred degree separation along theouter ring from each other for optimum pair separation that optionallyincludes the optional addition of one or more conductors (274) includingoptionally organic or inorganic fibers such as polyamide (for exampleKevlar®) filling and an optional strength member (272) within the secondinner ring.

FIG. 2D is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring. Also, betweenas few as one and as many as six of the extending projections,additional daisy-like spacers (280) (as shown in FIG. 4A) are placedwhich themselves allow for spacing of individual conductors or conductorpairs (282).

FIG. 2E is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring. Also, betweenas few as one and as many as six of the extending projections are shownwithout (284) the additional daisy-like spacers (FIG. 5A).

FIG. 2F is a cross-section view of another embodiment of the cablesupport-separator that includes the same symmetrical core with a centralcircular ring region as for FIGS. 1A and 2A but with an inner smoothring section with as few as two and as many as six extending protrusionseach extending in a preferred degree separation along the outer ringfrom each other for optimum pair separation that optionally includes theoptional addition of one or more conductors including optionally organicor inorganic fibers such as polyamide (for example Kevlar®) filling andan optional strength member within the second inner ring. Also, betweenas few as one and as many as six of the extending projections,additional spacers (290) comprised of a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design (as shown in FIG.6A) are placed which themselves allow for spacing of individualconductors or conductor pairs.

FIG. 3A is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (300) with four extending smooth protrusions (310,312, 314, 316), each protrusion extending less than those of FIGS. 1Athrough 2F, each again extending in a preferred 90 degree separationfrom each other for optimum pair separation .The central ring portionoptionally includes a hollow region (320) to act as an air blown fiber(ABF) duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 3B is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 1A through 2F, each againextending in a preferred 90 degree separation from each other foroptimum pair separation and also includes a second inner ring (330)within the hollow region comprised of a different material than theouter ring for either increasing lubricity or friction. The central ringportion optionally includes a hollow region to act as an air blown fiber(ABF) duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 3C is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with four extending smooth protrusions, eachprotrusion extending less than those of FIGS. 1A through 2F, each againextending in a preferred 90 degree separation from each other foroptimum pair separation and also includes also includes a second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections (340). The central ring portion optionally includes ahollow region to act as an air blown fiber (ABF) duct which is availablefor filling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIGS. 3D and 3E are cross-section views of another embodiment of thecable support-separator that includes a symmetrical core with a centralcircular ring region with as few as two (370 and 372 in FIG. 3E) and asmany as six extending smooth protrusions (350, 352, 354, 356, 358, 360in FIG. 3D), each protrusion extending less than those of the series ofFIGS. 1A through 2F, each again extending in a preferred separation fromeach other for optimum pair separation and also includes also includes aan optional second inner ring within the hollow region comprised of adifferent material than the outer ring for increasing friction utilizingrifled inner spatially arranged sections. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 3F is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region with no extending protrusions (380) that includesalso an optional second inner ring within the hollow region comprised ofa different material than the outer ring for increasing frictionoptionally utilizing rifled inner spatially arranged sections. Thecentral ring portion optionally includes a hollow region to act as anair blown fiber (ABF) duct which is available for filling with opticalfiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 4A is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region (400) with four extending protrusions (410, 412,414, 416) each protrusion extending less than those of FIGS. 1A through2F and each with at least a single cross-like section (420, 422, 424,426) extending outward from the circular ring section in a preferred 90degree separation from each other for optimum pair separation. Thecentral ring portion optionally includes a hollow region (430) to act asan air blown fiber (ABF) duct which is available for filling withoptical fiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 4B is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of FIGS. 1A through 2F, each again extending in a preferred90 degree separation from each other for optimum pair separation andalso includes a second inner ring (440) within the hollow regioncomprised of a different material than the outer ring for eitherincreasing lubricity or friction. The central ring portion optionallyincludes a hollow region to act as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 4C is a cross-section view of another embodiment of the cablesupport-separator that includes a symmetrical core with a centralcircular ring region and each with at least a single cross-like sectionextending from the circular ring section, each protrusion extending lessthan those of Figures through 2F, each again extending in a preferred 90degree separation from each other for optimum pair separation and alsoincludes a second inner ring within the hollow region comprised of adifferent material than the outer ring for either increasing lubricityor friction. The inner portion of the hollow ring region here isoptionally filled with inorganic or organic fibers (450) such aspolyamide fiber (Kevlar®) and at least four single or multimode fineroptic units (460, 462, 464, and 466).

FIGS. 4D and 4E include a cross-section view of another embodiment ofthe cable support-separator that includes a symmetrical core with acentral circular ring region with as few as two (470 and 472 in FIG. 4E)and as many as six (450, 452, 454, 456, 458, and 460 in FIG. 4D)extending protrusions each with at least a single cross-like section,each protrusion extending less than those of FIGS. 1A through 2F, eachagain extending in a preferred separation from each other for optimumpair separation and also includes also includes an optional second innerring within the hollow region comprised of a different material than theouter ring for increasing friction utilizing rifled inner spatiallyarranged sections. The central ring portion optionally includes a hollowregion to act as an air blown fiber (ABF) duct which is,available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 4F includes a cross-section view of another embodiment of the cablesupport-separator includes a symmetrical core with a central circularring region with no extending protrusions (480) that includes also anoptional second inner ring within the hollow region comprised of adifferent material than the outer ring for increasing friction utilizingrifled inner spatially arranged sections. The central ring portionoptionally includes a hollow region to act as an air blown fiber (ABF)duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces.

FIG. 5A is a cross-section view of another embodiment of the cablesupport-separator that includes a hollow four-petal (510, 512, 514, and516) or “daisy” shaped arrangement with a central core (500) that may ormay not be hollow (520 shown hollow). If the central region is hollow,the possibility again exists for that region to act as an air blownfiber (ABF) duct which is available for filling with optical fiber.Coaxial or twisted pair conductors may also be introduced in thatregion.

FIG. 5B is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal (540, 542, 544, and546) or “daisy” shaped arrangement with a central core (530) that may ormay not be hollow (532 shown hollow). Each “petal” contains two hollowsections (550 and 552) for additional optical or metallic conductormedia. The central region (532) is hollow allowing for the possibilitythat this region may act as an air blown fiber (ABF) duct which isavailable for filling with optical fiber. Coaxial or twisted pairconductors may also be introduced in that region.

FIG. 5C is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core (560) that may or may not be hollow.Each “petal” contains three hollow sections (570, 572, and 574) ofdiffering diameters for additional optical or metallic conductor media.The central region (560) is solid.

FIG. 5D is a cross-section view of another embodiment of the cablesupport-separator that includes a solid four-petal or “daisy” shapedarrangement with a central core that may or may not be hollow. Each“petal” contains three hollow sections of differing diameters foradditional optical or metallic conductor media. In this case, the centerhollow section of each petal is filled with an optical fiber unit (580).The central region is solid or optionally hollow.

FIGS. 6A, 6B, 6C are cross-sectional views of another set of embodimentsof the cable support-separator that includes a circular ring region(600) which is surrounded by rounded lobes (610, 612, 614, and 616) in asymmetric diamond-like geometry that defines as many as four separateregions for pairs that are properly separated in the final (oftenjacketed) cable design. Again the central ring portion can optionallyinclude a hollow region (620) that may be used as an air blown fiber(ABF) duct which is available for filling with optical fiber which iscomprised of solid, semi-solid, foamed or hollow polymeric smoothinternal and external surfaces. FIG. 6A has no inner ring, FIG. 6B has asmooth inner ring (630) with optionally different material than theouter ring, and FIG. 6C has an inner ring (640) with rifled sections(642). Each can optionally be used for coax or twisted pair as well asfor fiber optic conductors in advance, during, or after installation.

FIG. 6D is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes the optional addition of one or more conductors includingoptionally organic or inorganic fibers such as polyamide (for exampleKevlar®) filling and an optional strength member (650) within the secondinner ring (that may or may not be rifled). Again the central ringportion can optionally include a hollow region that may be used as anair blown fiber (ABF) duct which is available for filling with opticalfiber (660, 662, 664, and 666) which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces.

FIG. 6E is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion filled with a fiber optic unit (670) as wellas four separated conductor pairs (680, 682, 684, and 686) in each ofthe regions defined by the symmetric diamond-like geometry of the cablesupport-separator. Again the central ring portion can optionally includea hollow region that may be used as an air blown fiber (ABF) duct whichis available for filling with optical fiber which is comprised of solid,semi-solid, foamed or hollow polymeric smooth internal and externalsurfaces.

FIG. 6F is a cross-sectional view of another embodiment of the cablesupport-separator that includes a circular ring region which issurrounded by rounded lobes in a symmetric diamond-like geometry thatdefines as many as four separate regions for pairs that are properlyseparated in the final (often jacketed) cable design. This designincludes a center portion with a second inner ring portion (690) filledwith a fiber optic unit (692) or other conductors as well as fourcross-like separators (694) (see FIG. 7A) in each of the regions definedby the symmetric diamond-like geometry of the cable support-separatorwithin which another, up to four pairs of conductors (696) are situatedand separated by the cross-like separator. Again the central ringportion can optionally include a hollow region that may be used as anair blown fiber (ABF) duct which is available for filling with opticalfiber which is comprised of solid, semi-solid, foamed or hollowpolymeric smooth internal and external surfaces.

FIG. 7A is a cross-section view of another embodiment of the cablesupport-separator that includes a more conventional cross-like separatorsection (700) with “rifled” sections (702 and 704, for example)extending outward into four quadrants (710, 712, 714, and 716) away fromthe central region (700) and is encased or covered within an outerinsulated layer (720) which is itself shaped in an identical crossexcept that the dimensions of this outer cross is larger than the rifledinner cross and functions as a “skin”. The inner cross-like portion maybe metallized by utilizing electroless or electrolytic platingtechniques over a thermoplastic film.

FIG. 7B is a cross-section view of another embodiment of the cablesupport-separator that includes the same more conventional cross-likeseparator section as with FIG. 7A except that this separator contains ashield (730) that extends along the horizontal axis and optionally alsoalong the vertical axis or both axes within the horizontal hollowportion (740) of the cross-like separator. This shield is comprised ofaluminum PET film and may be configured so that it is held within theouter cross-like separator (720) and may also be part of an overallshielded cable which is shielded using aluminum backed PET film or abraided metallic shield or any combination.

FIG. 8A is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “zig-zag” extensions (810, 812, and 814, forexample) that extend away from the central region (800). Again thecross-like “zig-zag” arrangement may be covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross are larger than the rifled innercross and functions as a “skin”. This design optionally includes fourseparated conductor pairs (820, 822, 824, and 826) in each of theregions defined by the symmetric diamond-like geometry of the cablesupport-separator.

FIG. 8B is a cross-section view of another embodiment of the cablesupport-separator that includes providing variations on a cross-likearrangement by adding “sickle-like” extensions (830, 832, 834, and 836)that extend away from the central region. Again the cross-like andsickle-like sections arrangement may be covered within an outerinsulated layer which is itself shaped in an identical cross except thatthe dimensions of this outer cross are larger than the rifled innercross and functions as a “skin”. This design optionally includes fourseparated conductor pairs (820, 822, 824, and 826) in each of theregions defined by the symmetric diamond-like geometry of the cablesupport-separator.

FIG. 9 is a cross-sectional view of another embodiment (900) withseveral hollow regions (910, 912, 914, for example) for blown fiber orany transmission media for present, future, or concurrent installationsusing the support-separator alone or in combination with a cable.

FIGS. 10A and 10B are cross-sectional views of another set ofembodiments of the cable support-separator that includes a circular ringregion (1000) which is surrounded by semi-rounded lobes (1010, 1012,1014, and 1016) in a symmetric star-like geometry that defines as manyas four separate regions for pairs (1020, 1022, 1024, and 1026) that areproperly separated in the final (often jacketed) cable design. Again thecentral ring portion can optionally include a hollow region (1030) thatmay be used as an air blown fiber (ABF) duct which is available forfilling with optical fiber which is comprised of solid, semi-solid,foamed or hollow polymeric smooth internal and external surfaces. FIGS.10A and 10B include views of optionally filled inner hollow regions suchthat each can optionally be used for coax or twisted pair as well as forfiber optic conductors (in advance, during or after installation). FIG.10A includes a view of this design including the optional addition ofone or more conductors including optionally organic or inorganic fiberssuch as polyamide (for example Kevlar®) filling and an optional strengthmember within the second inner ring (that may or may not be rifled).FIG. 10B includes a view of this design that includes the optionaladdition of coaxial cable (1002) in the hollow center region. Thecentral circular region (1001) is of a slightly larger size than thatshown in FIG. 10A in order to allow for coaxial cable in the centralhollow region of the separator.

1. A high performance communications cable comprising; an interiorsupport with an external radial and axial surface, extending along alongitudinal length of said communications cable, said interior supportalso having a central region, said central region also extending along alongitudinal length of said interior support and said communicationscable; said interior support comprising at least one symmetrical corewith either a diamond-shaped or circular center outer hollow ring regionwith an optional inner central diamond-shaped or circular hollow ringregion with optionally extending protrusions each extending in apreferred separation from each of said other extending protrusionsextending from said outer hollow ring region.
 2. The high performancecommunications cable of claim 1, wherein said central ring portionoptionally includes a hollow region acting as a ductlet for an air blownfiber (ABF) which is available for filling with optical fiber(s) orother conductor(s).
 3. The high performance communications cable ofclaim 1, wherein said interior support, and said central circular regionshaped core support-separator sections comprises solid, partially solid,or hollow, foamed organic or inorganic dielectric materials.
 4. The highperformance communications cable of claim 1, wherein said interiorsupport, and said central circular region shaped core support-separatorsections comprises solid, partially solid, or foamed thermoplastic orthermosetting dielectric materials
 5. The high performancecommunications cable of claim 1, wherein channel walls of said centralcircular ring region with extending protrusions are corrugated includinginternal axial grooves separated by a sufficient distance such thatindividual conductors or conductor pairs maintain required electricalintegrity and such that said conductor or conductor pairs are optionallyforced against an edge of said grooves or sections of said channelwalls.
 6. The high performance communications cable of claim 5, whereinsaid interior support comprises a corrugated or convoluted externalradial and axial surface extending along a longitudinal length of saidcommunications cable, such that external surfaces of said symmetricalcore with a central circular ring region include external radial groovesalso extending along said longitudinal length of said support such thatsaid interior support can itself function as a cable jacket for saidcommunications cable.
 7. The high performance communications cable ofclaim 1, wherein said at least one symmetrical core with a centralcircular ring region with said protrusions are optionally singularlyfilled with individual or paired metal or optionally coaxial electricaltransmitting conductors or optical fiber light transmitting conductors,or filled with a combination of said individually or paired metal oroptical conductors along said longitudinal length of said support andsaid cable.
 8. The high performance communications cable of claim 7,wherein said metal conductors are copper with or without metallicshielding and said cable optionally comprises a form of metallicshielding.
 9. The high performance communications cable of claim 8,wherein said metal conductors are aluminum with or without metallicshielding and said cable optionally comprises a form of metallicshielding.
 10. The high performance communications cable of claims 1-9wherein said cable comprises one or more axial strength members whereinsaid axial strength members optionally lie parallel to said interiorsupport inside said communications cable jacket or within said hollowportion of said interior support along said longitudinal direction ofsaid support and said cable.
 11. An interior support-separator for acommunications cable extending along a longitudinal length of saidcommunications cable, comprising; an external radial and axial surface,said interior support also having a central region, said central regionalso extending along a longitudinal length of said interior support andsaid communications cable; said interior support comprising at least onesymmetrical core with a central circular ring region with an optionalinner central circular ring region with extending protrusions eachextending in a preferred separation from each of said other extendingprotrusions.
 12. The interior support-separator for a communicationscable of claim 11, wherein said central ring portion optionally includesa hollow region acting as a ductlet for an air blown fiber (ABF) whichis available for filling with optical fiber or other conductors.
 13. Theinterior support-separator for a communications cable of claim 11,wherein said interior support, and said central circular region shapedcore support-separator sections comprises solid, partially solid, orhollow, foamed organic or inorganic dielectric materials.
 14. Theinterior support-separator for a communications cable of claim 11,wherein said interior support, and said central circular region shapedcore support-separator sections comprises solid, partially solid, orfoamed thermoplastic or thermosetting dielectric materials.
 15. Theinterior support-separator for a communications cable of claim 11,wherein channel walls of said central circular ring region with fourextending rifled protrusions that are corrugated including internalaxial grooves separated a sufficient distance such that individualconductors or conductor pairs maintain required electrical integrity andsuch that said conductor or conductor pairs are optionally forcedagainst an edge of said grooves or sections of said channel wallswherein said interior support comprises a corrugated or convolutedexternal radial and axial surface extending along a longitudinal lengthof said communications cable, such that external surfaces of saidsymmetrical core with a central circular ring region include externalradial grooves also extending along said longitudinal length of saidsupport such that said interior support can itself function as a cablejacket for said communications cable.
 16. The interior support-separatorfor a communications cable of claim 11, wherein said interior supportcomprises a corrugated or convoluted external radial and axial surfaceextending along a longitudinal length of said communications cable, suchthat external surfaces of core-support sections include external radialgrooves also extending along said longitudinal length of said supportsuch that said interior support can itself function as a cable jacketfor said communications cable.
 17. The interior support-separator for acommunications cable of claim 11, wherein said at least one symmetricalcore with a central circular ring region with said protrusions areoptionally singularly filled with individual or paired metal oroptionally coaxial electrical transmitting conductors or optical fiberlight transmitting conductors, or filled with a combination of saidindividually or paired metal or optical conductors along saidlongitudinal length of said support and said cable.
 18. The interiorsupport-separator for a communications cable of claims 11-17 whereinsaid metal conductors are copper with or without metallic shielding andsaid cable optionally comprises a form of metallic shielding.
 19. Theinterior support-separator for a communications cable of claim 18,wherein said metal conductors are aluminum with or without metallicshielding and said cable optionally comprises a form of metallicshielding.
 20. The interior support-separator for a communications cableof claims 12 and 19 wherein said cable comprises one or more axialstrength members wherein said axial strength members optionally lieparallel to said interior support inside said communications cablejacket or within said hollow portion of said interior support along saidlongitudinal direction of said support-separator and said cable.
 21. Ahigh performance communications cable comprising; an interior supportwith an external radial and axial surface, extending along alongitudinal length of said communications cable, said interior supportalso having a central region, said central region also extending along alongitudinal length of said interior support and said communicationscable; said interior support comprising a hollow four-petal daisy shapedarrangement with a central core that may or may not be hollow, each ofsaid hollow petals separated by 90 degrees along an axial plane thatextends along a complete length of said communications cable allowingfor individual or paired conductors to be placed within said hollowpetals.
 22. The high performance communications cable of claim 21wherein said central portion of said four-petal daisy optionallyincludes at least one hollow region acting as a ductlet for an air blownfiber (ABF) which are available for filling with optical fiber(s) orother conductor(s).
 23. The high performance communications cable ofclaim 21, wherein said petal portions of said four-petal daisyoptionally includes at least one hollow region acting as a ductlet foran air blown fiber (ABF) which are available for filling with opticalfiber(s) or other conductor(s).
 24. An interior support-separator for acommunications cable comprising; an interior support with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said interiorsupport comprising a hollow four-petal daisy shaped arrangement with acentral core that may or may not be hollow, each of said hollow petalsseparated by 90 degrees along an axial plane that extends along acomplete length of said communications cable allowing for individual orpaired conductors to be placed within said hollow petals or withinhollow sections of otherwise solid petals.
 25. The interiorsupport-separator of claim 24, wherein said central portion of saidfour-petal daisy optionally includes a hollow region acting as a ductletfor an air blown fiber (ABF) which is available for filling with opticalfiber(s) or other conductor(s).
 26. The high performance communicationscable of claim 24, wherein said petal portions of said four-petal daisyoptionally includes at least one hollow region acting as a ductlet foran air blown fiber (ABF) which are available for filling with opticalfiber(s) or other conductor(s).
 27. A high performance communicationscable comprising; an interior support with an external radial and axialsurface, extending along a longitudinal length of said communicationscable, said interior support also having a central region, said centralregion also extending along a longitudinal length of said interiorsupport and said communications cable; said interior support comprisingan inner cross-like separator section with rifled sections extendingoutward into four-quadrants away from said central region, saidquadrants defined by 90 degree right angles formed by an intersection ofsaid extended cross-like rifled separator sections encased within anouter insulated layer which is itself shaped in an identical cross-likepattern as said cross-like separator section so that dimensions of saidouter insulated layer forms a cross-like pattern larger than said rifledinner cross and functions as a skin for said inner cross-like pattern.28. The high performance communications cable of claim 27, wherein saidcentral portion of said inner cross-like separator with said outerinsulated layer optionally includes a hollow central region acting as aductlet for an air blown fiber (ABF) which is available for filling withoptical fiber or other conductors.
 29. An interior support-separator fora communications cable comprising; an interior support with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said interiorsupport comprising an inner cross-like separator section with rifledsections extending outward into four quadrants away from said centralregion, said quadrants defined by 90 degree right angles formed by anintersection of said extended cross-like rifled separator sectionsencased within an outer insulated layer which is itself shaped in anidentical cross-like pattern as said cross-like separator section sothat dimensions of said outer insulated layer forms a cross-like patternlarger than said rifled inner cross and functions as a skin for saidinner cross-like pattern.
 30. The interior support-separator of claim29, wherein said central portion of said inner cross-like separator withsaid outer insulated layer optionally includes a hollow central regionacting as a ductlet for an air blown fiber (ABF) which is available forfilling with optical fiber or other conductors.
 31. A high performancecommunications cable comprising; an interior support with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said interiorsupport comprising a cross-like separator section with zig-zag sectionsextending outward into four quadrants away from said central region,said quadrants defined by 90 degree right angles formed by anintersection of said extended cross-like zig-zag separator sections. 32.The high performance communications cable of claim 31, wherein saidcentral portion of said cross-like separator with said extended zig-zagsections optionally includes a hollow central region acting as a ductletfor an air blown fiber (ABF) which is available for filling with opticalfiber or other conductors.
 33. An interior support-separator for acommunications cable comprising; an interior support with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said interiorsupport comprising a cross-like separator section with zig-zag sectionsextending outward into four quadrants away from said central region,said quadrants defined by 90 degree right angles formed by anintersection of said extended cross-like zig-zag separator sections. 34.The interior support-separator for a communications cable comprising asin claim 33, wherein said central portion of said cross-like separatorwith said extended zig-zag sections optionally includes a hollow centralregion acting as a ductlet for an air blown fiber (ABF) which isavailable for filling with optical fiber or other conductors.
 35. A highperformance communications cable comprising; an interior support with anexternal radial and axial surface, extending along a longitudinal lengthof said communications cable, said interior support also having acentral region, said central region also extending along a longitudinallength of said interior support and said communications cable; saidinterior support comprising a cross-like separator section with zig-zagsections that have sickle-like ends at each of said sections zig-zagsections and extend outward into four quadrants away from said centralregion, said quadrants defined by 90 degree right angles formed by anintersection of said extended cross-like zig-zag separator sections withsaid sickle-like ends.
 36. The high performance communications cable ofclaim 35, wherein said central portion of said cross-like separator withsaid extended zig-zag sections with said sickle-like ends optionallyincludes a hollow central region acting as a ductlet for an air blownfiber (ABF) which is available for filling with optical fiber(s) orother conductor(s).
 37. An interior support-separator for acommunications cable comprising; an interior support with an externalradial and axial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said interiorsupport comprising a cross-like separator section with zig-zag sectionsthat have sickle like ends that extend outward into four quadrants awayfrom said central region, said quadrants defined by 90 degree rightangles formed by an intersection of said extended cross-like zig-zagseparator sections with sickle-like ends.
 38. The interiorsupport-separator as in claim 37, wherein said central portion of saidcross-like separator with said extended zig-zag sections with saidsickle-like ends optionally includes a hollow central region acting as aductlet for an air blown fiber (ABF) which is available for filling withoptical fiber(s) or other conductor(s).
 39. An interior support of claim11, providing a specified lay length by implementing a twisting of saidhollow central region thereby providing said lay length twist into saidsupport-separator prior to manufacturing said final communications cableassembly.
 40. A method for producing a high performance communicationscable by introducing an interior support-separator section or sectionswith a longitudinal length, said external radial and axial surfaceshaving a central region extending along said longitudinal length of saidinterior support with said one or more hollow central ring portionsoptionally jacketed to complete said cable by; passing a plurality oftransmission conductors within said hollow central ring portions of saidinterior support-separator through a first die that aligns the pluralityof transmission conductors with surface features of said internalsupport allowing for intentional twisting of said conductors, forcingeach of said plurality of conductors into said hollow central regionring portions of said interior support-separator where said hollowcentral ring portions maintain a spatial relationship between each ofsaid transmission conductors by optionally; shielding and jacketing saidinterior support containing each of said conductors within said hollowcentral region sections and; optionally pulling each of saidtransmission conductors through said hollow ring portion(s) or saidsupport-separators either before during or after initial installation.41. The method of producing a cable of claim 40, by omitting the step ofjacketing said cable.
 42. A high performance communications cablecomprising; an interior support-separator with an external radial andaxial surface, extending along a longitudinal length of saidcommunications cable, said interior support also having a centralregion, said central region also extending along a longitudinal lengthof said interior support and said communications cable; said supportcomprised of a thermoplastic based material capable of meeting specificflammability and smoke generation requirements as defined by UL 910,NAPA 262, and EN 50266-2-x, class B test specifications.
 43. A method ofupgrading a communications cable between a first node and a second noderemote from the first said communications cable comprising an interiorsupport; said interior support comprising optionally at least onesymmetrical core with a central circular ring region with optionallyextending protrusions each extending in a preferred degree separationfrom each of said other extending protrusions, wherein said central ringportion optionally includes a hollow region acting as a ductletextending from the first node to the second node and the duct containinga first transmission line which extends between the first and secondnodes, the method optionally comprising the steps of: attaching a supplyof compressed gas to the duct at said first node; flowing gas from saidsupply of compressed gas along said duct from said first node to saidsecond node to cause viscous drag forces to act on said firsttransmission line, and withdrawing said first transmission line fromsaid duct under the action of said viscous drag forces; introducing asecond transmission line into said duct at one of said nodes, supplyingcompressed gas to said duct at said one of said nodes to cause a flow ofgas between said one node and said other node; and; advancing saidsecond transmission line from said one node to said other node undersaid action of viscous drag forces caused by action on said secondtransmission line by gas flowing from said one of said nodes towardssaid other of said nodes.
 44. A method as in claim 43, wherein saidfirst transmission line comprises at least one multimode optical fiberand said second transmission line comprises at least one single modeoptical fiber.
 45. A method as in claim 44, wherein said firsttransmission line includes at least one electrical conductor and saidsecond transmission line includes at least one optical fiber.
 46. Amethod as claimed in claim 45, wherein said at least one optical fiberis a single mode optical fiber.
 47. A method as claimed in claim 43,wherein said transmission line can include any transmission type media.